Metal Fabrication & Thermal Management

metal fabrication capabilities

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Metal Fabrication Technologies

Boyd Corporation has a longstanding history in innovative metal science solutions which has been augmented recently by the 2017 acquisition of Aavid Thermalloy. The acquisition of Aavid, the most recognized thermal solutions provider in the world, also included other leading global thermal brands like Thermacore Inc., Niagara Thermal Products, and Allcast. Thermacore Inc. played a pivotal role in the development and commercialization of two phase cooling technologies such as heat pipes as well as metal and material sciences for advanced cooling systems. Niagara Thermal Products serviced the aerospace and defense markets and was best known for their expertise with heat exchangers. While Allcast had a long history in industrial-focused die casting, including but not limited to complex thermal solutions. These pioneering histories rich in thermal innovation and material science continue today as a core tenet of the thermal and metal science solutions portfolios of Aavid, Thermal Division of Boyd. Combine that with Boyd Corporation’s own knowledge and expertise and you have a leader at the forefront of Metal Sciences with unsurpassed capabilities and capacity.

Boyd Corporation offers a vast metallurgic knowledge combined with diverse metalworking capabilities that enable the design and manufacture of superior thermal management and general industrial components and assemblies. We produce streamlined standard options as well as custom engineered solutions for prototype or production.

Our processes range from converting small thermal interface materials to the machining and brazing of large complex enclosures and everything in between. Thermal engineers utilize this range of manufacturing options to ensure that thermal solution and system designs feature the most appropriate technologies and construction choices.

Global Engineering Support

Boyd’s approach to custom metal solution design begins with working to understand our customers’ performance needs, challenges, dimensional constraints, and other requirements and aligning these needs with manufacturable and scalable solutions. Boyd hosts a global team of over 300 engineers that work closely with our customers to design optimized solutions and streamline production methods. Our engineers span a diverse range of fields including thermal, electrical, mechanical, manufacturing, and chemical engineering.

Our global engineering teams assist customers through the full product lifecycle from prototype to volume production to end of life management or retrofit utilizing a range of technologies and solutions. This wide variety of capabilities allows our engineers to better innovate and design creative, out-of-the-box solutions that employ multiple technologies for smaller, more powerful products.

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Quality Metal Products

As with all our products, Boyd is dedicated to ensuring the quality of our metal science solutions. Quality management systems span ISO9001 to AS9100, TS16949 and ISO13485 as well as environmental management systems certified to ISO14001. Solutions also go through rigorous testing and validation for performance assurance to confirm that our solutions meet or exceed your requirements with fully equipped quality laboratories, externally certified G, D&T quality technicians and various tools for process qualification like CPK analysis, FAI submittal, customer/product specific traceability, Gage R&R study/analysis and MiniTab software

Certifications include:
IATF 16949
ISO 13485
ISO 14001
ITAR Compliance
AWS D17.1 Specification for Fusion Welding for Aerospace Applications and certifications
AWS B2.2:2010 Specification for Brazing Procedure and Performance Qualification
AWS C3.3 Recommended Practices for the Design, Manufacturer, and Examination of Critical Brazed Components
AWS C3.4 Specification for Torch Brazing
AWS C3.7 Specification for Aluminum Brazing
AMS 2678 Furnace Brazing of Part in a Vacuum Atmosphere
AMS 2750 Pyrometry
AMS 2770 Heat Treatment of Wrought Aluminum Parts
Employees certified as Aerospace Qualified Welders (certified to AWS D17.1 and MIL-STD 1595A), AWS Qualified Brazers (certified to AWS B2.2), and Certified Welding Inspectors (certified to AWS QC1 Standard).

Metal Manufacturing Capabilities

Boyd Engineers maintain a focus on DFM, Design for Manufacture, and are trained to find the most suitable and cost-efficient fabrication method from Boyd’s wide range of manufacturing capabilities, including but not limited to die casting, machining, metal joining, metal extruding, complex metal stamping and folding, heat pipe processes, brazing, and APG production. Many of these manufacturing processes allow for the use of varying metal alloys and materials that our engineers can utilize for better performance or more stringent design specifications.


k-Core® System Fabrication, including Annealed Pyrolytic Graphite (APG) Growth
Heat Pipe, Vapor Chamber, and Loop Heat Pipe Fabrication
Liquid Cooled Cold Plates and Liquid Cooling System Fabrication, Assembly, and Integration
Machining, Heat Treating, Quenching, and Aging
Metal Joining: Soldering, Welding (TIG, MIG, plasma, inert gas, braze), Friction Stir Welding, Vacuum Brazing, CAB Brazing, Dip Brazing, Torch Brazing, Epoxy Bonding
Interface Material Conversion
Heat Sink Fin Fabrications: Skived, Extruded, Folded, Zipper, Bonded
Sheet Metal Fabrication

Additional Processes:
Counter boring
Cutting (sawing)
Deburring (automated)
Slotting, drilling (CNC)
Machining (EDM)
Stamping (high speed)
Epoxy isolation
Fly cutting
Milling (CNC)

Equipment Includes:
Continuous belt sintering and brazing furnaces
Controlled atmosphere retort furnaces
Controlled atmosphere precision ovens
Solder belt oven
CVD furnace
Vacuum braze furnace
Vertical and horizontal CNCs
CNC lathes
Heavy-duty presses
Robotic TIG welder
Automated plasma welding systems
Controlled atmosphere welding stations
Ultrasonic cleaning systems
Custom fixtures, assembly equipment and thermal test station
Helicoil insertion gun
Pemsert press
Schmidt press

Chemical Processes:
Chromate Hex
Chromate Non - Hex
Vapor Degrease - Trichlor
Stencil / Marking
Stamp / Marking

Manufacturing Quality Assurance Capabilities:
Fully equipped quality laboratories
Numerous quality certifications (ISO 9001-2000, AS9100, ISO14001)
Externally certified G, D&T quality technicians
Process qualification (CPK analysis, FAI submittal, customer/product specific traceability, Gage R&R study/analysis, MiniTab software)
Extensive ANSI and MIL standards expertise such as AWS D17.1 and MIL-STD 1595